Process of making pile fabrics



Sept. 21, 1943. J. L. BAKER PROCESS OF MAKING FILE FABRICS Filed April21, 1942 f/EDDLES W/ f/VESS. 5 w

Patented Sept, 21, 1943 Myinvention-frel aises to ih'e weaving (if-pilefabrics and comprises a hyel process for fria-kiixg a dqubie pile fabriccompr sed" of we *fa'irirics *(each' 'comprisingiwo series (ifbihdi'rig' threads, one series "of staffer warp mews,

weft yarns) "-cerin'eciiedby one or morefiir'eferably =two )'-series ofp il Warps boimiio-ii 1&6 biibh fabrics! 'The -fabricfprpduced by the pgeese Comprises a doiible jabric composedei 13w irigle ffabrieseachcontaining igi'iio setsdf bihfler wares, *a set of 'sfluffer war'ps'-and; pairs' of filler -01 were threads, o'he' fiwo "single-fabrics"being Mffified 59 threads 'commen to bdch'fabricsi' A ra-seman- :mthehboi/e desgtripiibhfifiti apr'tieess' =df- 'il'ikiflg it aredisclosedin liefifiersffateht for a-iom adapted-1 to weave 'such'afabric, No". 2,285, '19'3- sued to me June 9, 1942, m an abpii'ca't idriflied May 2 1, 1941QS 8Y. NO. 394,409, alSd iir I "seem No. 439,831."The present in ntiori; howe er; is animprovemenfi dn the-prdeessdeseribd iri 'saidmatent and e'nrtiddies' ether "featiires that; are

fiereifia fter deseribed and claim d.

both shuttles tiraverseihe 16pm, first air we 5 stuifer warp of theupper fabric; f the stuffer warp of the lower fabric; g and h the weftyarns of the upper fabric; 2' and a the weft yarns of the lower fabric;172 and n the pile warps, each of which is common to both fabrics.

The warp heddles are manipulated to form four sheds having onearrangement of warps alternating with four sheds having anotherarrangement of warps. In Fig. 2, the four sheds are formed by theseveral warps. as follows:

( 1) Between binder warp a and stuffer warp e (2) Between pile warp mand binder warp b.

(3) Between binder warp 'c and pile warp n.

(4) Between stuifer warp and binder warp d.

The alternate sheds, illustrated in Fig. 3, are formed as follows:

(5) Between binder warp b and stuffer warp e.

(6) Between pile warp n and binder warp a;

(7) Between binder warp d and pile warp m..

(8) Between stufler warp J and binder warp c; At each side of the loomare provided two weft yarn supplies. In one specific embodiment of theprocess, a bobbin carrying a supply of weft yarn g and a bobbin carryinga supply of weft yarn 2' are arranged at one side (say the left side) ofthe loom; and a bobbin carrying a supply of weft yarn hand a bobbincarrying a supply of weft yarn j are arranged at the other side of theloom. Shuttles 0,;p, r and s are provided for the four warp sheds. Eachshuttle is of the ty e, herein; before described, shown and describedin. my said patent.

After one beat of the lay and the formation of sheds I, 2, 3 and 4hereinbefore described, shuttle o engages the supply of yarn g and,traveling from left to right, pulls a double pick thereof through shedI; shuttle p engages the supply of yarn h and, traveling from right toleft, pulls a double pick thereof through shed 2; shuttle r engages thesupply of yarn i and, traveling from left. to right, pulls a double pickthereof through shed 3; and shuttle sengages the supply of yarn and,traveling from right to left, pulls a double pick thereof through shed4. All the shuttles travel simultaneously.

.Each .of the shuttles, after it completes its traverse, releases theweft that it -has pulled through the described warp shed.

The paths of .the four. shuttles, in their described traverse' of theloom, are, of course, at J different levels. Immediately after the fourshuttles traverse the loom as described, shuttle o is dropped from theuppermost level to-the next level below it and shuttle p is raised fromthe latter levelto the uppermost level; while shuttle s is lifted fromthe lowest level to the next level above it and shuttle r is droppedfrom the latter level to the lowest level. -After the next beat of thelay and the formation of sheds 5, 6, I andr8 hereinbefore described,shuttlep engages thesupply of yarn g and, traveling from left to rightpulls a double pick thereof through shed 5; shuttle 0 engages the supplyof yarn h and, traveling from right to left, pulls a double pick thereofthrough shed 6; shuttle s engages a supply of yarn i and, traveling fromleft to right, pulls a double pick thereof through shed l and shuttle rengages the supply of yarn and, traveling from right to left, pulls adouble pick thereof through shed 8. i H

Succeeding movements of heddles and shuttles are repetitious, of theabove operations, which results in the formation of a double fabric likethat shown in Fig. 1.,

As the. woven doublefabric islffed intermite tently forward, theconnecting pile yarns m and n are severed by a cutter and the two fabricare wound around spike rolls, as disclosed in my said patent.

The disclosure of mechanism to effect the above described operations isunnecessary, since such mechanism is fully illustrated and described inmy said patent. However, the process embodying my invention is notdependent for its operation upon any particular mechanism. Indeed, asidefromthe necessity, from a practical commercial standpoint, of providingapower loom adapted to practice the process, its practice is notdependent upon any particular mechanism. For example, the fabric may bewoven on a handoperated loom.

While the mechanism for effecting the above described operations may beconsidered to involve little more than a duplication of the mechanismillustrated and described in my said patent,

neither the process nor the resultantfabric constitutes a mereduplication, since the sheds are so formed that; there is produced, nottwo double fabrics each like the double fabric produced by the patentedloom, but only one double fabric.

That is, both of the processes produce double fab; rics, alike in thateach single component fabric comprises two sets of binder warp and a setof stuffer warps, there being a set of pile warps common to bothfabrics. While the fabric produced by the specific processhereindescribed contains an additional set of pile warps common to bothfabrics, one of them might be omitted.

The two fabrics, however, differ in thatin the fabric disclosed in mysaid patent the single set of pile warps connect half th pairs of wefts'of one fabric with half the pairs of wefts of the other fabric; whilein the fabric produced by the process embodying the present inventioneach of the-two sets of pile warps connects one-fourth of the pairs ofwefts Of one fabric with one-fourth of'the pairs of wefts of the otherfabric.

As above stated, it is not essential toutilizetwo sets of pilewarpasince eithenthe'pile warps m or the pile warps 11 maybe omitted,and in such a fabric, also, the single set of pile warps connectsone-fourth of the pairs of wefts ofone fabric with one-fourth of thepairs of.;wefts ,of the other fabric. i T 1 The advantage of the presentprocess, therefore, over the process practiced-in the said patented loomis not that it produces two double fabrics instead of one double fabric,but that it produces one double fabric havingfeatures in common with,but not identical with, the fabric disclosed in the patent, at twice thespeed at which the double fabric of, the patent is produced, andtherefore at much over four times the speed of production of a singlefabric on an ordinary pile fabric loom; Considering the factor of higherpracticable speed of travel ,of the shuttles and the factor ofcontinuous operationwithout replenishment of the shuttles,. the speed ofpro; duction approximates, ene exceed. five times the speed ofproduction' of the" ordinary loom.

As one of a number of possible modifications} eachof the shuttles may atall times traverse the loom on the same level, first in one directionand then in the other direction. ,This modification would necessitate-the employment of eight yarn supplies, fourl'at each sid'iofthe loom;,1,

Less desirably, instead ofutilizingfour shuttles, of t kind des ribednfim said tstsntiwhish are adapted to pull a 'double pick of yarn across 'lo ch" serratere e e- "c r ew tween :the second named two sheds of binderwarp threads, and simultaneously inserting double picks of weft yarnbetween all of said sheds: thereby forming two woven fabrics, eachcomprising two sets of binder 1 warp threads united by pile threadscommon to both fabrics and engaging every fourth double pick of weftyarn.

5. The herein described process of weaving pile fabrics which comprisesmanipulating four sets of binder warp threads, two sets of stuffer warpthreads and pile warp threads to form four sheds, one shed between oneset ofbinder warp threads and one set of stufier warp threads, anadjacent second shed between pile warp threads and a second set-ofbinder warp threads, a next adjacent third shed between a third set ofbinder warp threads and the second set of stuffer warp threads, and anext adjacent shed between the second set of stufier warp threads andthe fourth set of binder warp threads, and providing four weft yarnsupplies; inserting simultaneously double picks of weft yarns betweenthe four sheds respectively and then releasing the yarns; thenmanipulating the four sets of binder warp threads to reverse therelative positions of the two first mentioned sets of binder warpthreads and of the two last mentioned sets of binder warp threads and somanipulating pile warp threads that the second shed is formed betweenthe first set of stuirer warp threads and the first set of binder warpthreads and that the third shed is formed between the fourth set ofbinder warp threads and pile warp threads; then inserting simultaneouslydouble picks of weft yarn between the four sheds respectively and thenreleasing the yarns: thereby forming two woven fabrics, each comprisingtwo sets of binder warp threads and a set of stuffer warp threads,united by pile warp threads common to both fabrics.

6. The herein described process of Weaving pile fabrics which comprisesmanipulating four sets of binder warp threads, two sets of stufier warpthreads and two sets of pile warp threads to form four sheds, one shedbetween one set of binder warp threads and oneset, of stufier warpthreads, an adjacent second shed between one set of-pile warp threadsand a second set of binder warp threads, a next adjacent thirdshedbetween a third set of binder warp threads and the other set of pilewarp threads, and a next adjacent fourth shed between the second set ofstuffer warp threads and the fourth set of binder warp threads, andproviding four weft yarn'supplies; inserting simultaneously double picksof weft yarns between the four sheds respectively and then releasing theyarns; then manipulating the binder warp threads and pile warp threadsto reverse the relative positions of the two first mentioned sets ofbinder warp threads, ,ofthe two last mentioned sets of binder warpthreads and of the two pile warp threads; then inserting simultaneouslydouble picks of weft between the four sheds; respectively and thenreleasing the yarns; therebyjforming two woven fabrics, each comprisingtwo sets of binder, warp threads and one set of stufierwarp threads,united bytwo sets of pile warp threads common to both fabrics.

7. The hereindescribed process of weaving pile fabric which comprisesmanipulating four sets of binder warp threads and two sets of pile warpthreads to formfour'sheds, one shed between one set of binder warpthreads and one set of pile warp threads, an adjacent second shedbetween said set of pile warp threads and a second set of binder warpthreads, a next adjacent third shed between a third set of binder warpthreads and the other set of pile warp threads, and a next adjacentfourth shed between the last named set of pile warp threads and thefourth set of binder warp threads, and providing four yarn supplies;then inserting simultaneously double picks of weft yarns betweenthe-four sheds respectively and then releasing the yarns; thenmanipulating the binder warp threads and pile warp threads to reversethe relative positions of the two first mentioned sets of binder warpthreads, of the two last mentioned sets of binder warp threads, and ofthe two sets of pile warp threads; then inserting simultaneously doublepicks of weft yarns between the four sheds respectively and thenreleasing the larn: thereby forming two woven fabrics each comprisingtwo sets of binder warp threads united by two sets of pile warp threadscommon to both fabrics.

8. The herein described process of weaving pile fabric which comprisesmanipulating four sets of binder warp threads and pile warp threads toform four sheds, one shed being between two sets of binder warp threads,an adjacent second shed between pile warp threads and one of the lastnamed sets of binder warp threads, and each of the next two shedsbetween the other two sets of binder warp threads, andproviding fouryarn supplies; then inserting simultaneously double picks of weft yarnbetween the four sheds respectively and then releasing the yarns; thenmanipulating the four sets of binder warp threads to reverse therelative positions of the two first mentioned sets of binder warpthreads and of the two last mentioned sets of binder warp threads and somanipulating pil warp threads that the first and second sheds are formedbetween the first named two sets of binder Warp threads, the third shedbetween pile warp threads and one ofthe second named two sets of binderwarp threads and the fourth shed between the second named two sheds ofbinder warp threads, then simultaneously inserting double picks of weftyam between the four sheds respectively and then releasing the yarns;thereby forming two woven fabrics, each comprising two sets of binderwarp threads united by pile threads common to both fabrics and engagingevery fourth double pick of weft yarn. l l

; JOSEPH L. BAKER.

